Presentation - Production Management

8/3/2019 Presentation - Production Management

1/62


2/62

MMM

Sr. No. Names Roll No.

1 AJANI KAJAL P. MM-10-01

2 SWAMIKUTTY ANISH RAJ MM-10-02

3 DHAS AMIT J. MM-10-08

4 JADHAV SAMIR S. MM-10-14

5 KAMATH VINAYAK R. MM-10-15

6 RAI ANIKET B. MM-10-23


3/62

Overview of Hindalco

Capacity - Aluminium:

Hindalco : 531 kt

Novelis : 2,943 kt

Capacity Copper : 500 kt

Turnover FY10:

Hindalco- Novelis

$ 13.7 bn.

Employees: 36,000


4/62

Renukoot

Taloja

Hirakud

Alupuram

MoudaSilvassa Belur

Hindalco :

Footprint inIndia

Muri

Belgaum

Kalwa

Kollur

Integrated Plant

Foil

FRP

Alumina

Extrusions

Sales offices:Mumbai, Delhi, Bangalore, Kolkata

DAHEJ

Copper Smelter


5/62

5

CMO

SBU HeadPrimary

SBU HeadExtrusions

SBU HeadRolled - Domestic

SBU HeadRolled - Exports

Central Market

Development

IT

Training &

Development

MarketingServices

MHO (Primary Metal, Rolled & Extrusions)

FRP & Extrusions has Independent Market Development Cell

Hindalco - Marketing Structure


6/62

6

A typical Product Structure

Hindalco - Marketing Structure

SBU Head- Flat RolledProducts

RMNorth RMEast R M - West R M South

Market

Development Cell

Business

Finance

ProductExecutive


7/62

7

Primary Aluminium

Ingots Wire Rods Billets

Major Usage : Auto Industry / Construction/ Electrical Industry


8/62

Primary Metal -Castings

STEERING KNUCKLE WHEEL SUSPENSION ARM

SPACE FRAME NODE GS BRACKET

High purity aluminium required to ensure grain structure

Control Arm


9/62

9

Extrusions

Major Usage : Building Industry, Industrial Machinery, Defence


10/62

Flat Rolled Products


11/62

COOK WARE


12/62

FAN BLADE & VENETIAN BLINDS


13/62

Semi rigid containers


14/62

Al - Containers


15/62

Pharma Foils- Printed


16/62

PP Cap & Vial seals


17/62

Vial seals


18/62

H V A C


19/62

H V A C


20/62

Flooring Sheets
http://images.google.com/imgres?imgurl=http://www.artistic-license-inc.com/b2b/pics/Aluminium_Alloy_Panel.jpg&imgrefurl=http://www.artistic-license-inc.com/b2b/furniture_stocks/1/&h=334&w=359&sz=36&hl=en&start=15&tbnid=8qQUjbtgj1DTGM:&tbnh=113&tbnw=121&prev=/images?q=aluminium+panneling&gbv=2&hl=en&sa=G


21/62

ALUMINIUM COMPOSITE PANELS


22/62

Building Sheets
http://images.google.com/imgres?imgurl=http://www.liangiap.com.my/wp-content/uploads/2007/10/pic81.gif&imgrefurl=http://www.liangiap.com.my/building-sheets&h=170&w=272&sz=49&hl=en&start=14&tbnid=JNvMGKLWqSHiNM:&tbnh=71&tbnw=113&prev=/images?q=aluminium+building+sheets&gbv=2&hl=en&sa=G


23/62

Curvomatic Roofings


24/62

Cabinets


25/62

Reflectors & diffusers


26/62

Lamp caps
http://www.fengying.com/?Action=Detail&ID=4http://www.fengying.com/?Action=Detail&ID=6http://www.fengying.com/?Action=Detail&ID=3


27/62

Metal Bridges


28/62

Electrical bus bars


29/62

Lithographic sheets

Process Flow


30/62

Process Flow

Al. Ingot

Rolling Ingot Continuous Cast Coil

Scalping

Soaking/Pre-Heating

Hot Rolling

Annealing

Cold Rolling

Finishing

Melting andCasting

(Direct ChillMethod)

Melting andContinuous

Casting

Profiling Roll Forming Circle Blanking SheetingShearing Coiling

Packing


31/62

Aluminium Ingots

C i C i P


32/62

Continuous Casting Process


33/62

A process/facility of production ofslabs of various desired dimensionsfrom molten metal by extracting

heat through direct cooling by water,keeping both metal flow &thermodynamics in equilibrium.

Direct Clill Slab Casting


34/62


35/62


36/62


37/62


38/62


39/62

Why Scalping ?

1. The outer surfaces of the ingots (both the flat surface and theedges) contain more of impurities, oxides and have greateralloy segregation.

2. For any critical application like those requiring for subsequent

rolling to thin or ultra thin gauges it is necessary to get rid ofthese surface impurities and segregation.

3. The depth of the unsound casting zone could be anything fromabout less than a millimeter to as high as 10 12 mm

depending on the casting technology, process controls and alloyof the cast.


40/62


41/62

Preheating, Homogenizing and

soaking:

1. Casting leads to some extent of alloy heterogeneity in theentire mass of the ingots.

2. This heterogeneity needs to be taken care so that the finalproduct shows uniform physical and chemical propertiesmuch needed for uniform and smooth behaviors in furtherprocessing.

3. In order this to happen, the ingots are heated as close to the

solidifying temperature as possible. This process is calledHOMOGENIZATION. It is best carried out at temperatureas close to the solidifying (solidus) temperature as possible.

Soaking Pit


42/62

Soaking Pit

Soaking Pit


43/62

INGOT

HEATER FAN

INGOT

TOP VIEW

COVER

HEATER

FRONT VIEW

Soaking Pit


44/62

1.Rolling is defined as the reduction of the cross-sectional area ofthe metal stock, or the general shaping of the metal products,through the use of the rotating rolls .

2.It allows a high degree of closed-loop automation and very

high speeds, and is thus capable of providing high-quality, closetolerance starting material for various secondary sheet metalworking processes at a low cost .

What do u mean by Rolling??

S h i D i f R lli P


45/62

Schematic Drawing of Rolling Process


46/62

Hot Rolling Mill converts preheated cast Aluminium slabs of thickness

approx. 305 /330 mm into a sheet/coil of thickness 6 to 9 mm bypassing the slab between work rolls for an integral number of times


47/62

Annealing:

is a particular process of Heat treatment used torelieve the metal from internal stresses by loosingstored energy.

Metal losses its stored energy in the following threestages:

Recovery

Recrystallisation

Grain growth


48/62

Remove internal stresses by heating to arelatively low temperature.

Dislocations start reducing and rearrangethemselves.

It does not affect grain structure.

It does not affect hardness & strength

Recovery:


49/62

Recrystallisation:

Strain free new grains are formed.Hardness and Strength decreasessharply.

Grain growth:

Grains grow in size due to combination ofindividual grains.Boundary area reduces, so total energydecreases and grains become stable.

Annealing Furnace


50/62

51

Annealing Furnace

GECA Annealing Furnace

Annealing Furnace


51/62

52

Annealing Furnace

Sunbeam Otto Junker

What is Cold Rolling ?


52/62

53

What is Cold Rolling ?Cold rolling is the process of getting desired

thickness of material by passing it through workrolls at normal temperature (Below Re-crystallization

temperature)

Angle of Bite

Cold Mill


53/62

54

4.00 MM

6.50 MM

Uncoiler Coiler

4 Hi Mill

Bridle

Pass LineRoll

Pinch Roll

Deflector

X-RayGauge control

VidimonShape control

Cold Mill

Bliss Cold Mill


54/62

55

Bliss Cold Mill

Davy Cold Mill


55/62

56

Davy Cold Mill

S i i & Fl i


56/62

Spinning & Flanging


57/62

Stretching


58/62

Bending & embossing


59/62

Blanking & shearing


60/62

Sheet Forming: a combination of Processes

5

Equipment - Roll Former


61/62

Equipment Roll Former

Gauge : 0.28-1.63 mm

Width : 800/950 for CR

795/920 for ICR

Length: 545 - 10000 mm (1875-7000 preferred range)

Consists of 2 rafts (for CR & ICR); 4 sub-rafts; 5 forming

rolls in each raft

Forming - from centre to side; last 3 rolls for widthadjustment


62/62

Documents

Presentation - Production Management